OK seems to be fine with that steady green light, even managed to pick up the test network ESSID using my XP laptop (I know ...). So it'll just be a question of getting the Z working with my network, cool. Thanks for you assistance.

Posting this from my Zaurus. Thought I'd post the results of my own stupidity! The part I was missing was the channel select. After my reinstall of Cacko I setup my WiFi connections immediataly setting the ESSID thereby removing the option to change the channel. I switched to ad-hoc for a bit and changed the channel to match my router and it connected fine. D'Oh!